Method, apparatus and system for lining conduits

ABSTRACT

Methods, apparatus or equipment and systems for lining conduits, e.g., preferably subterranean pipelines and passageways, such as sewers, with a liner impregnated with a curable resin in order to secure the conduit against ingress or egress of liquids.

RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/639,886 filed on Feb. 18, 2020, which is a national stage applicationclaiming the benefit of priority from International Patent ApplicationNo. PCT/US18/00335 filed Aug. 20, 2018, which claims the benefit ofpriority from U.S. Provisional Patent Application No. 62/547,690 filedon Aug. 18, 2017, the disclosures of which are hereby incorporated byreference in their entirety.

FIELD OF THE INVENTION

The present invention relates to methods, apparatus or equipment andsystems for lining conduits, e.g., preferably subterranean pipelines andpassageways, such as sewers, with a liner impregnated with a curableresin in order to secure the conduit against ingress or egress ofliquids.

BACKGROUND OF THE INVENTION

Subterranean passageways that have been in use for many years tend tobecome permeable, thus permitting fluids to seep into and out of thepassageways. The necessary repair of such passageways is both anexpensive and time-consuming operation. Systems of lining passagewaysthat use a fabric impregnated with curable resin have been used for anumber of years. Such systems and methods of lining passageways aredisclosed, for example, in U.S. Pat. Nos. 4,009,063; 4,064,211;4,135,958; 4,685,983; 4,668,125; 6,679,293; 5,154,936; Re. 35,944;6,390,795; 4,752,511; 5,044,405; 6,708,728; 6,354,330; 6,682,668;6,827,526; 6,641,687; and 5,969,234. Each of the foregoing references isincorporated by reference herein.

U.S. Pat. No. 4,009,063 to Wood discloses a method of lining apassageway, wherein a tubular fibrous felt is immersed at the passagewaysite in a thermosetting resin. The resulting resin-impregnated felt hasan inflatable tube therein which is inflated to shape the resin to thepassageway surface. As the tube is lowered into the passageway (e.g., asewer), the tube is pulled along the passageway by winding up a ropeattached to a leading end of the tube onto a hand winch. The tube can beinflated, e.g., with air under pressure from a fan or blower. With thetube so inflated, the uncured resin is either allowed to cure naturallyor is cured under the action of heat depending upon the type of resinused. The resin is cured to form a hard, rigid lining pipe with the feltembedded therein.

U.S. Pat. No. 4,064,211 to Wood discloses a method for liningpassageways, wherein a resin-impregnated foam or felt in the form of aflattened tube liner is anchored at one end of a passageway and fed intothe passageway being turned inside out as it is fed in. Before the lineris turned inside out, it is supported buoyantly by liquid, e.g., water,which serves to carry the liner. The liquid also forces the tube to rollinside out inside the passageway, the uneverted portion being suspendedin the liquid. When the tube is partially filled with and floats on theliquid, the remainder of the tube may be filled with air under pressure.After the complete lining of the passageway, an outer barrier layer ofthe tube may be removed therefrom.

U.S. Pat. No. 4,135,958 to Wood discloses a method of lining apassageway with a resin absorbent tube, involving causing a tube ofresin absorbent material to evert into the passageway by applying fluidpressure to the interior of the everted tube to force the unevertedportion of the tube to move into the passageway through the evertedportion of the tube; causing a reservoir of resin to be located in theuneverted portion of the tube which is just behind the portion of thethat is everting into the passageway, whereby the resin absorbentmaterial is soaked by the resin in the reservoir just before thatmaterial everts; and supporting the uneverted tube at the location ofthe reservoir of resin by means that move along the passageway as thetube everts, e.g., a balloon or gas-filled bag.

U.S. Pat. No. 4,685,983 to Long, Jr. discloses a method and apparatusfor installing a flexible tubular liner into a pipe, by means ofpressurized air. Wherein the apparatus includes means for defining apressurized region for inserting the liner into the pipe and aninsertion conduit, having an entry end and exit end connected to themeans defining the pressurized region. Means are provided on the exitend of the insertion conduit for sealing and clamping the leading end ofthe liner to the exit end of the insertion conduit and for creating afluid tight seal between the liner and the insertion conduit. The lineris installed within a sewer pipe by securing the leading end of theliner to a fixed structure adjacent to one end or within the sewer pipeand by inverting the liner or turning the liner inside out along thelength of the sewer pipe. Once the liner reaches the halfway point inthe insertion process, all of the liner is located within the sewerpipe. The apparatus functions to insert the liner within the sewer pipeusing fluid pressure, which can be a combination of water pressure andair pressure. Air pressure is made to act upon a column of water placedin the insertion conduit to push downwardly a cuffed leading edge of theliner, thereby causing the liner to invert and move the turned backportion of the liner toward the left along the sewer pipe. Pressurizedfluid flows through the pressure conduit to facilitate the bending ofthe liner through the diversion angle. The inversion and movement of theliner along the sewer pipe continues until the inversion end reaches andabuts against a stop means, which has been placed inside of the sewerpipe at the end of the section of pipe to be lined. Static waterpressure forces the liner radially outwardly against the walls of thesewer pipe. Hot water is pumped through a hot water pipe into the hose,which extends along the length of the liner. Through this circulationprocess, the water temperature within the liner is slowly raised to atemperature sufficient to effect curing of the liner resin.

U.S. Pat. No. 4,668,125 to Long, Jr. discloses a self-contained,transportable apparatus for inserting a flexible liner into a pipe,wherein the apparatus includes an inversion means or insertion conduit,and means for sealing and clamping a leading end of the liner with afluid tight seal to the insertion conduit or inversion means. Theapparatus further includes a water pipe secured to one side of theinsertion conduit and adapted to be connected to a source of water, anda plurality of water valves located along the length of the water pipeto control the flow of water through the water pipe. During use of theapparatus, the leading end of the liner is moved down the insertionconduit until it extends out of the exit end of the pipe. The leadingend of the liner is then turned inside out for the first six inches toform a cuff which is pulled back over the outside of the insertionconduit exit end and is secured using a clamping means. The water valvesare then opened to allow water to flow through the water pipe and toenter the top of the insertion conduit. Because the leading end of theliner is secured to the insertion conduit exit end, the water will becontained within the insertion conduit and will fill the insertionconduit. As the water pressure within the insertion conduit builds up toa predetermined level, the water pressure causes the liner to invert andmove along the pipe. The water continues to flow into the insertionconduit to maintain the water pressure at a level sufficient to move theliner along the pipe. When a trailing end of the liner reaches theinsertion conduit entry end, the operation is stopped and a rope issecured to the trailing end of the liner. When the liner has beencompletely inverted and inserted into the pipe, the liner is cured.

U.S. Pat. No. 6,679,293 to Driver discloses a process for lining anexisting pipeline with a flexible resin impregnated cured in place linerby pulling in the liner and inflating an eversion bladder with air andcuring the liner with flow-through steam without loss of pressure. Thebladder is everted by means of pressurized air. Steam is introduced intothe bladder to cure the resin, after which the bladder is removed.

U.S. Pat. No. 5,154,936 and Re. 35,944, both to Driver et al., disclosea tube eversion apparatus for use in lining passageways, e.g.,underground sewer pipes, wherein the apparatus is composed of a housinghaving an open top and an open bottom through which a tube to be evertedcan pass. The housing is composed of first and second chamberscommunicating with one another by a passage defined at least in part bya flexible wall, through which passage the tube is adapted to pass withthe flexible wall in engagement therewith. The housing further includesa third chamber with the flexible wall defining a surface thereof. Thehousing also contains a means for supplying fluid to the first chamber,means for supplying fluid at an elevated pressure to the second chamber,thereby to evert the tube out from the apparatus, and means forsupplying fluid at an elevated pressure to the third chamber, thereby topress the flexible wall against the tube as the tube moves through thepassage, so as to substantially rate the first and second chambers andto retain the elevated fluid pressure in the second chamber. Theflexible wall may extend substantially completely around the passage,thereby forming a sphincter valve which is moved to a closed,tube-engaging position by the fluid pressure in the third chamber. Thefluid used to provide the pressure to evert the tube is preferablywater. The pressure provided to the third chamber is preferably airpressure and is selected to effectively substantially seal off the upperend of the third chamber (thus separating the first and second chambers)while permitting the tube to slide there through.

U.S. Pat. No. 6,390,795 to Waring et al. discloses an apparatus for usein installing a liner in a conduit as part of a repair procedure,wherein the apparatus includes a sealing inlet port for passage of thetubular liner into an enclosed zone where an increased fluid pressure ismaintained to move the tubular liner into the conduit and to evert it asit moves along the conduit. The apparatus also includes a container forholding air or another fluid under pressure to act on the flexible tube.The sealing inlet port is provided in the container to allow the linerto enter the container in a flattened configuration without significantloss of pressure, so that the pressure of the fluid in the container canbe used to evert and extend the tubular liner into the required positionwithin a conduit.

U.S. Pat. No. 4,752,511 to Driver discloses a method and apparatus forsealing the space between a pipe and a lining applied to the pipe'sinterior, wherein sealing rings are provided between the lining and thepipe to prevent fluid from passing through spaces between the pipe andthe lining. The patent further teaches that water or other fluid is usedto evert the liner into and along the interior of the pipe.

U.S. Pat. No. 5,044,405 to Driver et al. discloses a method andapparatus for repairing short sections of pipe by lining them. Thepatent teaches that patch type repair is accomplished by locating thelining within a carrier, which is inserted into the pipe to be repaired,and moved to a position adjacent the length to be lined. The lining isthen moved out from the carrier into position within the pipe, with thecarrier providing means for pressing the lining against the interior ofthe pipe and causing it to assume final form. After the lining is formedin situ, the carrier is separated therefrom and removed from the pipe,ready for reuse. To remove the lining from the carrier, fluid pressureis applied to the liner to cause it to evert and move away from thecarrier.

U.S. Pat. No. 6,708,728 to Driver et al. discloses a “pull in andinflate” method for lining a pipeline with a flexible resin impregnatedcured in place liner. Liner is pulled into a pipeline section to berelined by pulling in the liner and inflating an eversion bladder withair and curing the liner with flow-through steam introduced in thebladder. After curing is completed, the bladder is removed.

U.S. Pat. No. 6,354,330 to Wood discloses a method of lining a pipelinewith a lining tube or resin absorbent material impregnated with acurable synthetic resin, wherein a lining tube is inserted into thepipeline and urged by pressure against the pipeline and heat is appliedin stages to lengths of the lining tube. Water is used to evert thelining tube in the pipeline.

U.S. Pat. No. 6,682,668 to Driver et al. discloses a process for liningan existing pipeline with a flexible resin impregnated cured in placeliner by pulling in the liner and inflating it with a reusable endlessinflation bladder. The bladder is everted by means of water.

U.S. Pat. No. 6,827,526 to Warren discloses an assembly for installing apipe liner within a sewer pipe, wherein the assembly includes a launcherdefining a passage through which the pipe liner and a bladder passduring installation into a branch line sewer pipe. An inflatable memberis mounted to an outer diameter of the launcher and is actuatablebetween an inflatable condition and a deflated condition. The inflatablemember defines an airtight cavity into which air is introduced by way ofan air inlet. A carrier tube is attached to the launcher body to provideprotected passage for the pipe liner and bladder tube. A seal isprovided between the launcher and the carrier tube. During installationof the pipe liner into a sewer pipe, the bladder is cuffed around theinflatable member and clamped around the outer surface of the launcher,and the pipe liner is then cuffed over the inflatable member on theoutside of the bladder. The pipe liner is impregnated with a curableresin before being installed onto the launcher. The launcher is thenattached to a positioning device (e.g., a rotating/lifting machine or asystem of cables including pulleys and cables attached to the launcherand operated to pull and guide the launcher) for movement into positionwithin the sewer pipe. The positioning device and the launcher areinserted into the main line of the sewer pipe and the launcher ispositioned relative to a discrete location within the sewer pipe. Theinflatable member is then inflated to trap the bladder and the pipeliner against the inner surface of the pipe. Air pressure is thenapplied to the bladder through the carrier tube to drive the bladder andthe pipe liner into the main line sewer pipe, which causes the entirelength of the pipe liner to be drawn through the passage defined in thelauncher. The inflatable member is then deflated, but the bladderremains inflated until the pipe liner hardens. Once the pipe linerhardens, the bladder tube is deflated and the launcher removed from thesewer pipe.

U.S. Pat. No. 6,641,687 to Kiest, Jr. discloses a pipe repair apparatus,which includes an outer carrier tube, an inner bladder tube within thecarrier tube, and a repair sleeve within the bladder tube. The bladdertube and the carrier tube are formed by one unitary tube, which isfolded back upon itself. A wick extends from the repair sleeve to therear end of the bladder tube and permits evacuation of gases from thebladder tube when the bladder tube is flattened by a vacuum duringinsertion of a curable resin into the bladder tube at its forward end.The bladder tube can be inverted out of the carrier tube so as to placethe repair sleeve in contact with an area to be repaired within a sewerpipe.

U.S. Pat. No. 5,969,234 to Weigele discloses an apparatus for repairingand/or leakage testing of sewer pipes, wherein the apparatus isconstructed as a tubular member surrounded by an elastic element, theapparatus further having an opening and a bladder. The bladder can beexpanded by means of an arbitrary medium, e.g., gas, air, or a liquid.Supporting wheels permit movement of the apparatus inside the sewerpipe. For repair of a damaged connecting point of a connecting pipeadjoining a sewer pipe, the opening in the apparatus is aligned with thedamaged connecting point. An interspace in the apparatus is filled witha medium, e.g., air, thereby causing the elastic element to expand andfill up the interspace. The elastic element bears against the sewer pipeinner wall and moves the apparatus up against the sewer pipe inner wall.The bladder is moved out through the opening into the connecting pipeand inflated, thereby causing the bladder to bear against the inner wallof the pipe and form a seal. Filler is then pressed into the region ofthe damaged connecting point and cured. The bladder is then reeled backinto the tubular member of the apparatus and the medium is let out ofthe interspace, thereby causing the tubular member to sink downward.

A drawback observed in many current pipelining systems is the need touse a thermal curing resin to impregnate the tubular liner, as it isthen necessary to maintain the resin at a significantly reducedtemperature in order to retard or hold back the curing process until theliner is fully inserted into the intended conduit or pipeline. Tomaintain the resin-impregnated liner at such reduced temperatures, theliner is initially cooled at a centralized liner preparation facility.During storage and/or transportation of the resin-impregnated liner fromthe liner preparation facility and the conduit to be lined, the linerhas to be kept under refrigeration. In this way, the liners can betransported a substantial distance to the remote job site, hopefullywithout any curing of the resin during transportation. By using acentralized facility for the preparation of the liner, the sameequipment can be used to impregnate and otherwise prepare linersconcurrently for different jobs at widely separated job sites, howeverthis is all extremely risky and very expensive.

Suitable resin concentration in the impregnated liner is determined atleast in part by the natural ability of the fabric material to absorbthe various resin liquids used in the impregnation, which again dependson the current temperatures as the resin viscosity also changes withtemperature at which the impregnation and the rate of impregnation canoccur. These rates will change depending on the materials, resin (e.g.,resin viscosity) and fabric (e.g., fabric density) used. To then use athermo-setting or heat activated catalyst resin, which may have to bestored for many weeks inside refrigerated containers or trucks (sincethe stability is very limited), results in the shelf life beingunreliable due to the thermal-activators utilized in the systems of theprior art. Another major issue with this type of heat curing systemoccurs mainly in gravity sewer pipes and deep conduits, and this is theeffect of cold groundwater creating a cold sink temperature drop thatmay interfere with the curing process of these liners, and coldgroundwater issues surrounding these underground pipes are mostlyunknown or hidden until the pipe is under internal pressure and thesefactors can cause very serious delays or dramatically extend the curingcycle, and this effect can be devastating, and in some instances, theliner does not fully cure causing another problem which is the now softuncured portion of liner forms into a blockage within the flow-line ofthe pipe and is called a “lift” in the liner which, then has to beexcavated as an emergency repair.

The use of a true ambient thermal cured resin which also has verysimilar groundwater or temperature related issues, and as such that inmost cases it's completely impractical, unless the process is used for asmaller length and diameter pipe or for a short-sectional repair (ashort length of tubular liner), used for all diameters that onlyrequires a partial repair to a section of the damaged conduit or pipe,or indeed to repair a section of previously failed liner), this is dueto the volume of resins normally required, and of the critical amountsof ambient activator/catalyst needed when this process is chosen, thetemperature of the resin, chemicals along with the liner have to becarefully monitored or controlled, and then the liner has to beinstalled immediately upon the completion of the mixing and saturationof the liner due to these critical relationships of mass resin/catalystand the predicted time to cure that's now affected immediately by thesurrounding temperatures. Another drawback to this method is that oncethe process of mixing has begun, the installation work cannot stop evenfor an emergency as the liner may start to cure prematurely, and for anumber of reasons, but mostly related to temperatures and therefore thistype of operation typically has to take place directly on site with veryhigh risks and costs. Another drawback which has created many documentsand papers from leading environmental groups, has been the concern andassociated risks with the release of a carcinogen namely “styrene” intowaterways or areas of aquatic life, most current pipelining materialshave an outer coating or membrane which when the liner is inverted intoplace then becomes the inside surface of the new pipe and thiscoating/membrane typically allows for the styrene gas to mitigate intothe pipe while curing, this practice is very dangerous, highly toxic toaquatic life downstream, and the odors can be very overcoming in closeconfinements.

Finally, it is both time consuming and very costly when these linershave to be installed completely before the mechanism for curing orinitiating the resin to cure by heating is started, therefore moreexpensive equipment, additional labor and time are required andnecessary to make these types of repairs for conduits or passageways ofvarying lengths and diameters.

It is desirable, therefore, to provide a new method, material andapparatus for installing these curable liners without any costlyrefrigeration transportation, expensive heating trucks and equipment. Itis also desirable, therefore, to provide a new method, material andapparatus for installing smaller diameter liners without any risk oftemperature, environmental and differing site conditions fromprematurely curing the liner or adding to the timing of the curingprocess, due to unpredictable risks associated with geographical weathervariations, unknown underground conditions and vulnerability,furthermore by removing the associated costs and risks of any possibletemperature variations from the installation method and practice, andthereby removing potential safety and quality control issues associatedwith the on-site mixing of liquid resins, retarding agents andtemperature activated catalysts when attempting to impregnate or resinsaturate the tubular liners on site. It is also desirable, therefore, toprovide a new method, material and apparatus for installing these linerswhich can be cured in position without being affected by any unforeseentemperature effects or environmental issues, it is also desirable tostart the curing of the resin saturated liner during the installationand prior to it being fully installed, thereby speeding up the entireprocess for any diameter of conduit or subterranean passageways and inany direction or grade that is used to carry liquids or gas, such assewage, in which the interruption of the passageway is minimized.

SUMMARY OF THE INVENTION

The present invention is directed, in part, to a method for inverting atubular liner in a hollow conduit, particularly a subterraneanpassageway or pipeline, e.g., a sewer pipe, storm drain, and the like.In addition, the present invention is directed to a method for lining ahollow conduit with a resin-impregnated tubular liner and a flexiblelight curing activator tube, an apparatus for inverting a translucenttubular bladder in a hollow conduit while inserting the flexible lightactivator tube to cure the liner as it is installed. In addition, thepresent invention is directed to a method for pulling or placing aresin-impregnated tubular liner along with the flexible light activatortube and a translucent bladder together in unison as one device, for thetubular lining of a hollow conduit or a partial section of it. Themethods are much simpler and faster than conventional methods forinverting or placing a liner in a conduit and for the curing of theresin impregnated liner, the methods and apparatus are more consistentand with less risks for use in an underground hollow conduit. Optionallythe methods, apparatus and system of the invention allow for the linerto be curing as the inversion or installation procedure takes place. Inanother aspect of the present invention, the methods, apparatus andsystems also minimize all the known associated risks and costs byremoving temperature as part of the equation in relation to heatassisted or ambient curing thermal resin mechanisms, and all of theirrelated costs along with the risks associated in the transportation, aswell as the potential time factors for the intended conduit to be closedor by-passed during the installation process and the curing stage of theresin-impregnated liner.

In one aspect, the present invention provides a method for inverting atubular liner in a hollow conduit comprising:

-   -   (a) forming a cuff from a leading end of an apparatus that has        an additional opening and securing the cuff of the tubular liner        to the leading opening of the apparatus;    -   (b) feeding a remainder of the tubular liner through the opening        in the cuff under pressure of a gas;    -   (c) sealing or clamping a region of the tubular liner after the        cuff, once a portion of the tubular liner has been inverted        within the hollow conduit, to ensure that the gas pressure        inside the inverted portion of the tubular liner is maintained;    -   (d) attaching a trailing end or tail of the tubular liner to a        flexible light curing activator,    -   (e) unsealing or unclamping the region defined in (c), thereby        allowing the inversion of the remainder of the tubular liner fed        through the opening in the cuff; and    -   (f) allowing the flexible light curing activator to start a        curing process while the trailing end of the tubular liner moves        in a forward motion through the entire length of the hollow        conduit being lined.

Optionally, on smaller diameters and short lengths, the liner can beinverted into the conduit through its entirety and a translucent bladderis then inverted in the same manner, except this inversion procedurepositions the translucent bladder inside of the tubular liner already inposition within the hollow conduit being repaired, by introducing gasinto the translucent bladder and causing the bladder to continue itsinversion inside the tubular liner. Before the trailing end of thebladder is fed through the device, the flexible light activator ispowered on to initiate the curing process, as the translucent bladderinverts itself through the tubular liner and, thereby, curing andinflating, causing the tubular liner to be held tightly in place againstthe host pipe by the translucent bladder, while curing the liner inplace all the way to the end.

In another aspect, the present invention provides a method of lining ahollow conduit with a tubular liner comprising:

-   -   (a) providing the tubular liner with a leading end;    -   (b) forming a cuff from the leading end of the tubular liner,        the cuff comprising an opening which is positioned outside of        the hollow conduit;    -   (c) securing and positioning the cuff of the tubular liner        before a first access opening of the hollow conduit;    -   (d) feeding a remainder of the tubular liner through the opening        of the cuff; and    -   (e) delivering pressurized gas through a gas inlet port into a        space defined between the cuff and the remainder of the tubular        liner inside a vessel or other device, while feeding the        remainder of the liner through the opening of the cuff, wherein        the pressurized gas exerts pressure inside the tubular liner,        thereby causing inversion and inflation of the liner into the        hollow conduit.

Optionally, at the halfway point of the tubular liner being inverted inthe conduit, restricting a region of the liner between the cuff and theexposed liner thereby temporarily restricts the liner while the flexiblelight activator is attached to the trailing end of the liner. Once therestriction is removed, the gas is allowed to pass through into theliner, thereby causing inversion, inflation and curing of the linerwhile the remainder of the liner is inverted through to the end.Additionally, the rate of curing is regulated by controlling the speedof the trailing end of the liner as its pulling the light activatorthrough the liner inside the conduit, maintaining or establishing apressure in an interior portion of the inverted liner such that thepressure is sufficient to keep the liner against the inside surface ofthe conduit. Most preferably, another step of curing the resin in theliner is introduced, as the trailing end attached to the light activatormoves through the entire liner towards the end, away from the initialstarting point.

In yet another aspect, the present invention provides for a method oflining a hollow conduit with a tubular liner, for use on partial repairsor to shorter sections of conduit or for smaller diameters and shortlengths of hollow conduits. The resin-lined tubular liner, inconjunction with a translucent bladder and flexible light curingactivator, can be pushed or pulled into place into the hollow conduit inits entirety, and then when in position, inflating the translucentbladder with a gas, which in turn presses the tubular liner tightagainst the host pipe or hollow conduit wall, before the flexible lightactivator device, which is central positioned within the translucentbladder and host pipe, is powered up to start the curing process.

In yet another aspect, the present invention provides for a method oflining a hollow conduit with a tubular liner, wherein the liner isimpregnated with a light-activated resin before the liner is inserted orplaced within the conduit.

In yet another aspect of the present invention, provided herein aremethods of this invention being carried out in the absence of anyheat-activated resin and, therefore, the liner does not require anyspecial cooling or large refrigerated trucks and can be installed invery hot climates without curing in advance of installation.Additionally, neither cold climates, presence of groundwater nor anyextreme temperature-related issues affect the curing process. The gas ispreferably air and the pressure of the gas is preferably from about 2 toabout 30 pounds per square inch (psi) covering all diameters. Operationat atmospheric pressure requires a supplemental force to invert theliner or bladder.

Preferably, once the liner or bladder is fully disposed within theconduit at the halfway stage, the methods of this invention may furtherinclude the step of sealing off the entrance to the device, (e.g., witha blank plate or cap and moving the inversion apparatus and anotherinsertion device to another location to facilitate additionalinstallations) and then proceeding with the remaining steps of themethods. The hollow conduit can be, for example, a water or gas pipe, astorm drain, a sewer pipe, a wastewater drain, or the like.

In another aspect of the present invention, there is provided anapparatus for inverting a tubular liner or bladder in a conduitcomprising:

-   -   (a) a feeding element comprising at least one opening through        which an activator is attached to a trailing end of the tubular        liner or bladder before a cuff is formed from a leading end of        the tubular liner or bladder; and    -   (b) a temporary securing or clamping element positioned        downstream of the feeding element, wherein the activator is an        electric light activator tube comprising a unit of sufficient        length to improve curing time and speed with a restraining        cable.

Optionally, at least one spiral centralizer is attached to the outsideof the activator to ensure that the electric light activator tube is ina central position relative to the conduit to cure the tubular liner asfast as possible during installation. Preferably, the electric lightactivator tube is flexible and also wrapped or encased with a passivereflecting tape to assist in dispersing UV light in all directions,Preferably, a braking control member is also provided, for regulatingthe speed of the inversion, pulling the activator through the liner orbladder and can be simultaneously viewed via a camera.

The above-described apparatus is also used to line a conduit with atubular liner in accordance with the method of the invention. Thepresent invention also comprises a combination of components with theabove-described apparatus. The additional components include knownapparatus to hold pressure and invert the liner or bladder, a viewingportal with a translucent screen and a UV protective filter built in toprotect the material and yet allow an operator to observe what iscontained within the device and monitor the special arrangement of thepower cable that is wound or coiled on the rollers contained within thedevice and externally on the reel to the power restraining cable, aportable battery or power supply to provide the low power electricalsupply which is connected to one end of the light activator and yetwired internally to provide power to both ends of the light activatortube, a flexible tube with a built in spiral flat portion placed atregular intervals to ensure that the flat and flexible circuit stripsremain in place on the outside of the hollow tube along with thecentralizers which keep the light activator tube towards the middle ofthe conduit even on very tight bends, while the multiple light sourcestrips are then positioned closer to the inside of the pipe wall, a unitto generate pressurized gas, the resin impregnated tubular liner with aUV protective sleeve and a portable monitoring unit to facilitate theabove method.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosed subject matter contained herein is best described inconjunction with the accompanying drawings, in which:

FIG. 1 shows a schematic illustration of a hollow conduit that is to berepaired using the apparatus of the present invention in a region havingat least two access points.

FIGS. 2A-F represent a schematic illustration of how the methods anddevices of the present invention move through a standard repair, inconjunction with a tubular liner inversion only, where the lining isdeployed at one access point in a two access point environment;

FIGS. 3A-3B show a schematic illustration of the light curing activatorused in FIGS. 2A-F for larger diameter pipes (6 inch and above); 3A isconsidered the standard or normal position; 3B is the activator shown inan expanded position, when the device is optionally inflated.

FIG. 4 is a schematic illustration of the method and apparatus of theinvention when used in conjunction with a shorter length partial tubularliner and a smaller and shortened version of the above translucentbladder including its flexible tube, combined with its centralizers andlow powered flexible light source as shown in the method of theinvention.

FIG. 5 is a cross-sectional and perspective illustration of the centralhollow and flexible tube, showing the design, surface mounting andplacement of the permanent lighting circuit strips, in addition to thespiral centralizers and their positioning, as well as the optionalreflecting tape wrapped around the entire tube length.

FIG. 6 is a schematic detail illustration of the flexible tube includingthe flexible light source circuits with the spiral centralizers whileinside the translucent bladder and under gas pressure of expansion topress the UV resin saturated tubular liner tight against the host pipeand to evidence the unique positioning effect when inside a very smallpipe bend.

FIG. 7 shows the inversion vessel of the present invention.

FIGS. 8A-H shows an exemplary illustration of the multi-stage method ofa preferred embodiment of the present invention, wherein the stages movesequentially from FIG. 8A through the end of the process (shown at FIG.8H) for smaller diameter, residential pipes.

FIG. 9 is an illustration of a small diameter packer showing thedisplacement to the flexible tube inside the encapsulation and thecoiling effect even with tethers connecting each end.

FIG. 10 is a simple wiring diagram showing the flexible light activatorand evidencing a preferred wire arrangement to both ends for both powerconsumption and rotational use as an option.

FIG. 11 is a schematic illustration to show a miniature version of thelight activator, inside a micro packer inflation device for very smalldiameter pipes.

DETAILED DESCRIPTION OF THE INVENTION

In the method of the present invention, a UV activated resin-impregnatedfabric tubing, having had its UV protective sleeve removed during theloading of the material from its transport container and into theinversion pressure drum or apparatus, the liner or bladder is drawnthrough the entrance of the apparatus of this invention sufficiently toallow the first few feet of the liner or bladder to be exposed insideout from the exit point of the apparatus. The first few feet of theliner or bladder to be exposed inside out from the exit point of theapparatus is preferably at least about 2 feet, more preferably fromabout 3 feet to about 5 feet, most preferably from about 6 feet to about15 feet, depending on the depth of the access to the pipe or conduit.

The liner tube or bladder is secured to the apparatus and a portion ofthe UV protective sleeve previously removed is positioned over the areaintended for the tubular liner to be inverted into (turned inside out)and thereby protecting the exposed resin impregnated fabric tubularliner from any light source exposure, the trailing end of the resinimpregnated fabric tubular liner can also be protected by a UVprotective sleeve and the trailing end or tail is secured or restrictedto ensure that the tubular liner or bladder cannot pass beyond theapparatus exit position when the inversion starts.

With the apparatus in position, air or fluid is forced under pressurethrough, a vessel container or other such device thereby only allowingonly air pressure, water or gas to enter into the tubular liner orbladder, causing the liner tube or bladder to expand, which in turnpulls the remaining liner or bladder through itself (inversion oreversion).

Internal pressure of the liner tube or bladder expands the materialtight to the inside wall of the conduit or pipe to be repaired and ismaintained by the air or fluid flowing through the apparatus into theliner tube or bladder, thereby forcing the material to conform to theshape of the existing passageway, pipeline or conduit. This sameinternal pressure causes the liner tube or bladder to pull the remainderof the liner tube or bladder through its own self, thereby propelling orinverting further into the passageway, pipeline or conduit. When thetube or bladder has reached the halfway stage of the intended length forthe installation, the trailing or tail end of the liner or bladder thatwas previously restricted from passing the device is held fast haltingthe inversion.

A clamp or restricting device can now temporarily be applied to theexposed liner tube or bladder exterior, and adjusted as such to restrictthe entrapped air gas or water from escaping out from the liner tube orbladder, a cap on the apparatus is removed, to allow the trailing end ofthe tubular liner or bladder, to be attached to the resin activator tubeif they are housed separately, from the liner or bladder tube inversionvessel or container. A closure cap can also be applied to the deviceopening. The container or vessel holding the light activator source cannow be attached to the apparatus or trailing end of the liner if housedseparately, and still maintaining the seal of internal pressure, onceattached the clamp or restricting device is removed, at the same time,optionally the liner vessel, container or other device if separate, canbe removed from site, to be then used optionally at another locationafter reloading with another resin-impregnated fabric tubular liner orbladder.

As the liner tube or the bladders trailing end or tail, travels past theexit point or cuff of the liner or tube, the activator which is nowpowered on typically by low voltage dc current, and sends power to thelights in its entirety which initiates the curing sequence of the UVresin-impregnated fabric tube already expanded into shape, and the shortcuring process begins, since the activator source is a minimum length of30 feet, (optionally 50 to 100 feet) the inversion process can continuewithout stopping, as the tail or trailing end is pulling the activatorthroughout the entire liner installation length, curing as it moves, sothat by the time the activator reaches the end of the intendedinstallation, the resin-impregnated fabric tube is now a hardened orcured pipe without joints and from the entry point to the furthest exitposition of the old pipe or conduit as needed to complete theinstallation.

The liner used in the present invention preferably has a thickness of atleast 2 millimeters. Particularly suitable thicknesses range from about2 millimeters up to about 18 millimeters. The diameter of the liner isat least 2 inches, with particularly suitable diameters ranging fromabout 3 inches to, e.g., 24 inches. Larger sizes can be accommodated bywiring more activators together and by providing more battery power.

The fabric forming the lining may be formed from at least one layer ofresin absorbent material, such as felt or glass fiber or a combinationof both. The resin impregnating the fabric is preferably a non VOCsynthetic light activated resin, which means that it will cure with theemissions of a UV light source within a few minutes, even under waterand without any environmental issues or strong odors.

Particularly suitable materials for forming conduit liners of improvedstrength are disclosed, e.g., in U.S. Pat. No. 6,837,273 and U.S.Published Application No. 2003/0234057, both of which are incorporatedby reference herein. These references disclose fabric layers, which aresewn or bonded, and which contain a natural or synthetic fibrousmaterial in needled, knit, woven or non-woven mat form. Suitablematerials should be water- and corrosion-resistant. Examples for suchfabrics include pulp fiber, hemp, cotton, and polyethylene,polypropylene, rayon, nylon and/or polyester fibers.

The references also teach that woven or non-woven glass material can beused in addition to, or as a substitute for, these other fibers.

The references further teach that the resinous impregnation liquidintroduced into the fabric layers can be any number of light activatedcompositions. The resinous impregnation liquid becomes set or hardenedby a UV light at a specific light range to activate the catalyst andprovide a solid matrix around the fibers. The suitable compositionsinclude a light-react-able agent. Such examples include ultravioletcuring unsaturated polyester or vinyl-ester or any non-VOC lightactivated resins, as disclosed in U.S. Pat. No. 6,170,531 (incorporatedby reference herein), e.g., vinyl ester.

The method and apparatus of this invention can be used to line a conduit(e.g., passageway or pipeline) in a vertical or horizontal position andof various shapes and dimensions regardless of disposition of theconduit to be repaired or lined. Non-limiting examples of suitableconduits to be lined according to the present invention include thosehaving a diameter of at least 2 inches, preferably from about 3 to 24inches, and those having a length of at least 30 feet, preferably fromabout 30 feet to about 400 feet. However, it is to be understood thatthe present invention is not restricted due to the dimensions of theconduit.

The conduit to be lined preferably extends between two access locations.Alternatively the reusable translucent bladder can be used for pipeswith only one access position, as the bladder will go further than theliner end, ensuring the downstream tubular liner is expanded and curedas the bladder moves through and out of the liner end.

Once the liner is cured the exit and entry point or just the entry pointcan be cut out allowing for the activator to be retrieved or pulled backthrough the pipe when only one access is available, the bladder and theactivator is retrieved with a minimal internal pressure of 1 psi toassist in the de-inversion process as its pulled back inside itself andout of the pipe to the cuff.

Embodiments of the apparatus and system of this invention and thevarious stages of the methods of the present invention will now bedescribed with reference to Stages 1 to 5, further referenced herein asFIGS. 2A-F, for larger scale installations where there are two mainaccess points for the pipe in need of repair

FIG. 1 shows a damaged conduit to be repaired or lined by the methodsand devices of the present invention. FIG. 2A describes an exemplarystage 1 situation, where conduit 10 to be lined (e.g., a sewer pipe) hasa first access opening in the form of manhole chamber 10A or cleanout, asecond access opening in the form of manhole chamber 10B, a firstvertical channel, and a second vertical channel. It is to be understoodthat combinations of vertical channels to conduits of various geometriesand diameters can also be lined using the methods, apparatus and systemof this invention.

Feeding element 4 is a conventional feeding member for receiving andfeeding a resin-impregnated fabric tubular liner 3 or bladder intomanhole 10A and eventually conduit 10, through entry apparatus 1. Entryapparatus 1 is located downstream of feeding element 4 and is adapted tofixedly secure an opening 1A of cuff 3A formed from a leading end ofliner tube 3 or bladder, with clamping member 5 located downstream ofcuff 3A and a gas-inlet connector 6 located upstream at feeding element4 and, also, light activator unit element 2. A UV light protectivesleeve 4A is shown, extending from feeding element 4 to entry apparatus1. Preferably, feeding element 4 comprises portal 8 for viewing andtransferring spent liner post-use.

Entry apparatus 1, optionally, may include a supporting frame to sit onor near manhole 10A or attached directly onto any liner feeding element4. Alternatively, entry apparatus 1 can be located directly at thebottom of any vertical chamber or clean out within manhole 10A.

The system of this invention includes an entry apparatus 1 incombination with light activator unit element 2 or feeding element 4 asa combination of both chambers if size or volume is not an issue such asfor smaller diameter installations. Light activator unit element 2,which comprises a long flexible tube encompassing a plurality of LEDlights that are pre-set to a specific wavelength in order to activatethe resin impregnated fabric liner as its being installed. Thislightweight hollow flexible tube of lights, also has the ability toexpand under pressure of an internal gas thereby allowing the tube thepossibility of expanding and changing its shape when inside the liner orbladder and therefore bringing the light arrays closer to the insidewall surface to increase curing speeds. Use of a passive reflecting tapealso helps to mirror the light available from the source and reflect itsemissions both outwardly and longitudinally inside the pipe or conduit.

As shown in FIG. 2A, conduit 10 is reached via a cleanout or manhole10A, most of which are vertical shafts. Liner tube 3 is attached tofeeding element 4 in preparation for installation within conduit 10. Asdiscussed above, liner tube 3 is formed of a resin absorbent fabric or adry bladder inflation tube and has a length that is equal to or greaterthan the distance between manholes 10A and 10B. Liner can be installedin increments from about 10 to about 500 feet, depending upon conduitdimensions, logistics and physical and weight demands.

As shown in FIG. 2B, and again in FIG. 8B, a leading end of liner tube 3is turned inside out for the first few feet to form cuff 3A over opening1A of entry apparatus 1 or light activator unit element 2 or feedingelement 4, which is then turned back over opening 1A and secured by aclamp to form cuff 3A.

The specific arrangement and design of cuff 3A is a matter of choice tothose skilled in the art. Entry apparatus 1, light activator unitelement 2 and feeding element 4 have openings by which liner tube 3 isfirst fed through to the exit point where the opening is used to formcuff 3A and secured or clamped onto entry apparatus 1 at opening 1A, oron the exit points at light activator unit element 2 and feeding element4.

Gas-inlet connector 6 is used upstream of cuff 3A and opening 1A toentry apparatus 1, and is normally located on light activator unitelement 2 and feeding element 4 to transmit air or gas from compressor 7into liner tube 3 or bladder contained inside a preferred vessel, whilefeeding the remainder of liner tube 3 through cuff 3A at opening 1A,with gas, which is preferably air or steam, being introduced from a gashose via gas inlet connector 6, through feeding element 4 and into aspace on entry apparatus 1, finally delivered through liner tube 3 orbladder. Between cuff 3A and the remainder of liner tube 3, there existsa space inside the feeding element 4 and entry apparatus 1, being ofequal pressure and being disposed inside liner tube 3, causing linertube 3 or bladder to expand and pull itself from feeding element 4 andthrough entry apparatus 1.

The gas is fed under pressure (e.g., from about 0 to about 30 psig) and,for a 24″ diameter conduit, this would typically require gas at 4-8psig. While an 8″ diameter conduit requires gas at 6-12 psi, a 4″diameter conduit may require gas up to 20 psi due to bends andrestrictions.

Increased pressures are initially required to invert all liners orbladders to the halfway stage, due to the frictional forces requiredwhen entering the pipe and pulling itself through itself, therebyturning inside out. Pre-lubricants on the liner or bladder can help inthis function. The gas introduced through gas in-let connector 6 isregulated by a valve to maintain pressure inside liner tube 3, therebycausing inversion and inflation of liner tube 3 into conduit 10.

As shown at FIG. 2C, once a portion of liner tube 3 or bladder(preferably 50%) has been inverted in conduit 10, the air supply at gasinlet connector 6 on feeding element 4 is closed via clamping member 5,thereby trapping all the air inside liner tube 3 or bladder downstreamof cuff 3A, since liner tube 3 or bladder has been completely dispensedout of feeding device 4.

As air is exhausted out from the feeding element 4 to atmosphere, cap 1Bis removed and the trailing liner tube 3 or bladder end is located andsecured to activator assembly 2A inside light activator unit element 2and through the exposed cap 1B. Light activator unit element 2 is thenattached to entry apparatus 1 and optionally feeding element 4 can beremoved and entry apparatus 1 is closed or capped at the location whereliner tube 3 previously entered (FIG. 2D). Powered light tube 2B isactivated at a time after air pressure is re-established via the othergas inlet connector 6 on light activator unit element 2. Clamping member5 is now removed and, optionally, feeding element 4, with its tubeconnector and protective sleeve 4A to entry apparatus 1 may be removedto be re-loaded with another UV resin impregnated fabric liner tube orbladder for another installation elsewhere.

In the final stages of the methods of the present invention, as shown inFIGS. 2D-E, as well as FIGS. 8D-E, the halfway point of the inversion ofliner tube 3 or bladder is now inside conduit 10 or pipeline, poweredlight tube 2B has been powered up and the light emission triggers theresin impregnated fabric tube to cure, while simultaneously, and under apre-regulated speed that limits the rate of inversion, pulls activatorassembly 2A through and inside itself (turning inside out) past cuff 3Auntil it reaches the final destination or length of the plannedinstallation inside conduit 10 or pipeline. Optionally the activatorassembly 2A can be fully positioned via the inversion technique or bypulling the combined activator and translucent bladder into position,and then inflating and powering up the powered light tube 2B to activatethe curing process. Another option is to fully invert activator assembly2A to the furthest point first, then setting the cure timing by the rateor speed of retrieval to cure liner tube 3 as necessary, all the wayback to the entry point of the conduit or pipe but now in a reversedirection.

Once the curing activator has reached the final position, powered lighttube 2B can be turned off and the unit retrieved from this positioninternally by reversing direction. If used in conjunction with a bladderor removable coating, the pressure is reduced to around 1 psig in orderto assist this process and activator assembly 2A is restored into thelight activator unit element 2 or other type of vessel. If activatorassembly 2A was used without a bladder, then liner tube 3 is cut open atthe entrance of 10B and the trailing end of the tubular liner can bedisconnected from the activator tube, thereby allowing activatorassembly 2A to be withdrawn manually, in reverse, and stored back insidelight activator unit element 2, feeding element 4, or other container.Having completed this operation, entry apparatus 1 can also be removedand any excess liner cured in the vertical sections of 10A and/or 10Bcan also be cut away, leaving the shaft clear for flow to enter. Whenclear and complete, the leading and trailing ends of the cured liner aresealed to the inside walls of the conduit so as to prevent seepage orleakage of water or other fluid between the liner and conduit (FIG. 2F).

Once the liner is cured in place, it may be necessary to cut openingsfor other conduits, which intersect or join with it. This can be doneusing a conventional motorized cutter that can travel the conduit linerto make appropriate openings. The device can include a camera to viewand record the cured liner.

The apparatus of the present invention has been described with regard toa specific embodiment. The concept present is in essence asimplification of known processes, in particular those directed to fluid(e.g., water) processes. The present design encapsulates gas to layliner in a conduit or pipeline while at the same time allowing the lightactivator to start the curing process as the tail or trailing end of thetubular liner travels the length of the intended installation.

Material to the design is the inlet ports made in a stationary portionof the apparatus to allow the liner to be fed through and then cuffed atthe exit point below the opening through which liner is fed, and ifnecessary another port to allow for the activator to enter the apparatuswhich can then be pulled through the tubular liner cuff by the trailingend of the tubular liner using the inversion process and without losingpressure.

Further material to the apparatus is the various designs of the lightactivator, in that the long continuous and flexible printed circuitry ofa stringed arrangement of specific and multiple UV LED components whichare now mounted on the flat portion of a specially designed roundflexible hollow tube by a spiral or longitudinal configuration on theoutside surface and yet inside a water tight translucent sleeve ortubular liner (FIG. 5). The flexible tube within an additionaltranslucent and flexible bladder encapsulating the light activator tubemay also be pressurized to inwardly expand the circuitry or deflect theflexible tube spirally to allow for more components to be attachedcircumferentially and in length, thereby putting the light emissionscloser towards the inside diameter of a host pipe or conduit intendedfor lining and thereby speeding the curing process for larger diameterpipelines or conduits. In addition, the design for a micro unit of avery small diameter 1 inch and a short length of up to 12 inches hasalso been developed primarily for the residential and commercialplumbing markets to use within very tight access pipes (FIG. 6). Theflexibility of the tube in FIG. 6 is shown, with its translucent bladder62, multiple LED lights 66 and centralizers 68, as expanded under gaspressure on the inside of a small diameter pipe or conduit bend. Asfurther shown, this flexible tube embodiment enables the pressing of theUV resin saturated tubular liner 64 tightly against the host pipe 60 orconduit for repair. Such a device can be negotiated through a 2 inch “P”trap to form a partial repair of approximately 4 to 6 inches in lengthto repair these pipes without excavation within buildings and basementsin similarity to Example I. The design for the optics on each LED isthrough an entire 360 degrees from its axis or radial position and eachled as a minimum backup led to one side or the other on the flexiblecircuit strip and then spread lengthwise and in a two way continuouspower circuit (power is supplied to both ends of the activator tube) onlengths normally at a minimum of 5 feet for partial repairs, and aminimum of 50 feet, preferably a 100 feet for bigger diameter pipes. Dueto the stress, fatigue and harsh conditions that the entire activatorand tube must endure, the overpopulation of LED lights has been designedinto the system so that if 1 or 2 LED lights fail for any reason theliner will still cure with just one or more remaining LED light, inaddition the optional use of the reflecting tape wrapped around theflexible tube, more than doubles the intensity of the available lightemissions within an enclosed pipe or conduit.

FIG. 7 provides for an alternative embodiment of the devices of thepresent invention. As shown in FIG. 7, a combination pressure and powerinversion vessel is provided for tubular liner combined with the deviceof FIG. 5 and FIG. 6.

FIG. 9 describes a device for use in a small diameter pipe, showing aninflated translucent packer. FIGS. 10 and 11 show the wiring connectionswithin the tubing for use in small diameter pipe applications.

EXAMPLES

The following examples describe specific methods within the scope of thepresent invention for lining or rehabilitating a pipeline or portionthereof. Each of the methods used a lining apparatus with variations andportions of the scope of the present invention. In each Example, priorto lining, the pipeline was temporarily removed from service and pluggedor capped or (i.e., bypassed) by plugging the pipeline one sectionupstream of the work area and pumping all flows overland to one sectiondownstream of the work area. The pipe to be lined was cleaned prior toinstallation of the liner.

Example I

The most recent example and use of the apparatus and method of theinvention occurred at a private residence in Phoenix Ariz. where theclimatic conditions precluded the use of a thermal cure process. Thecontractor a large private plumbing company had entered into a contractto repair approximately 24 feet of old 3 inch cast iron sewer pipe thathad failed in several locations along the bottom of the pipe, allowingfor raw sewer to flow underneath the house foundations and when theflows backed up other services had to be called in to clean the insideof the home in question. The contractor had chosen a spray type ofprocess initially to fix the problems encountered however during thedescaling and additional prep-work needed to help restore the old castiron pipe, further damage ensued causing more holes to form only thistime their positions were closer to the top of the pipe or at the 12o'clock position.

To solve this problem, three separate partial tubular liners were putinto place, rather than line the entire length due to the fact thatseveral other connecting secondary pipes fed into the same main sewerunder the building and the additional disruption and costs associatedwith lining over a connection would result in having to excavate underthe flooring or in the walls. The methods and equipment, as detailedpreviously, were selected and utilized together with a combinationpush/power hose attached to an enclosed translucent enclosed bladder asshown in FIG. 4, with the exception that the unit was deployed upstreamand going underneath the property proximate to a small pit excavated forwaste and ingress/egress. t A camera was pushed to the furthest repairpoint needed in order to measure the length of repair required, whichwas to be approximately 3.5 feet by 3 inch in diameter. Once the camerawas removed and the exact measurements transferred to the push hose anddevice, under a light protective canopy in the back yard and intemperatures away above 100 degrees, the protective sleeve encasing theraw materials for which we had previously saturated a UV resin wasremoved, prior to using, as the tube was cut to the required lengthneeded. The protective sleeve was resealed for the remaining rolls ofresin saturated material, the wet material was placed around the outsideof the device and rolled it into as tight a position. A few elasticbands were applied to help retain the circular shape and in consistentwith keeping the device as small as possible, the device was theninserted into a flexible UV resistant tube and taken to the pit to bepushed into the pipe while at the same time removing the protectivetube, once in the pipe the device was pushed very easily up to therequired position navigating a few bends along the way. At the correctlength position known from the previous measurements and being confirmedby pushing the video inspection camera inside the pipe to the back ofthe device and monitoring the device, the air supply which feeds throughthe push/power hose and special connectors, was turned on and set at 12psi. In a few seconds the bladder on the device had expanded, therebypushing the resin liner tight to the host pipe and covering the damagedarea. Once the bladder could not be moved forward or backward, the lowpower supply from the battery unit was engaged and current wastransmitted inside the same single push/power hose, which in turnpowered the UV LED circuit inside the device. Within three minutes, theliner had cured to form a new section of pipe albeit a partial lengthremotely placed underground and beneath the home. The power was turnedoff at this time and the air supply was extinguished and the connectionto the small compressor opened to atmosphere allowing air previouslytrapped in the bladder to escape. Within seconds, the bladder was freefrom its expanded state and the device removed from the new pipesection. The video inspection camera was again deployed to verify therepair was successful and that the broken section had been now coveredby the structural repair cast in place. The device and materials wereused over the next 45 minutes to complete two more repairs in the samepipe using the same procedure and equipment as described above. By allaccounts, this is the first time a pipe repair for this small of adiameter has been completed using a UV resin and an LED low power lightactivator in the USA.

Example II

Another example of the method and a part of the device of the inventionoccurred at a location underneath a major highway within San DiegoCounty. This involved a major problem associated with a small, 10 inchdiameter storm drain of approximately 120 feet in length that ran undera very busy intersection. The traffic diversionary problems encounteredwith this location and multiple lanes with heavy traffic flows requiredan alternative pipe rehabilitation method, as this had to be completedon site and as fast as possible and in high elevated temperatures. Thishighlighted the known issues in the present state of the art in thisfield of technology, including problems such as the methods andprocedures for such an operation cannot occur all at the same time, thepipe needed extensive cleaning which could take several hours in orderto prepare the pipe for a repair, the actual reason for the repair orthe cause could not be clarified since the inspection cameras could notget through the pipe, and there was no desire to claim responsibility topay for the equipment labor and material costs, without a guarantee thatthe pipe could actually be repaired without excavating the entireintersection. Specialty contractors on pipe rehabilitation wereunwilling to take the risks associated with the time allowed to actuallywork on the site while not knowing if indeed any possible payment couldbe applied without knowledge of what accounting method could be used inthis issue, as they had deemed it an emergency. For which the owneralready had a contractor under obligation as an emergency contractor.None of the known pipe rehabilitation contractors were recommended dueto the high costs and the extensive, unknown risks involved, or even ifthe pipe could be repaired internally. Not one manufacturer of materialfor use with pipe rehabilitation was willing to resin impregnate atubular liner with a thermo-setting resin, without knowing how much timewas available to hold the liner inside a costly refrigeration truck.Additionally, no contractor was willing to take the risk of having allthe material ready and available on site for a thermal cure, ambientresin mix and installation type of operation, when nobody could confirmthe true internal diameter or its real length, or if the pipe couldactually be repaired internally without trenching.

The methods and devices described supra were utilized to solve thisproblem, starting late at night, which meant the UV resin liner could beremoved without canopies or UV protective sheeting. The tubular linerwas loaded into the device as described within this invention and someof its methods as shown in FIGS. 2A-2F. Within 25 minutes, the tubularliner was attached to the power cable and inverted through to the othercatch basin located in the median of the freeway. Shortly thereafter,the apparatus was inside the liner and, after 10 more minutes, the speedof inversion was calculated and set to move forward at approximately 12feet per minute.

Example 3

Another example of the benefits of the methods and devices of thepresent invention occurred at a canyon location. A number of stormdrains had been designated for repair using the standardcured-in-place-pipe (CIPP) process. However, the contract was severelydelayed from all bidding due to local fires and eventually the projectwas withdrawn due to an unforeseen issue that occurred in anotherlocation within the county, whereby a previously lined storm drain thathad been repaired with a CIPP liner product caught fire and,consequently, the fire spread underground up through the storm pipe andappeared in an area where the fire personnel had previously thought thehome was safe from issues. As a result of these circumstances and afterthe county had reviewed all options, the revised specifications wouldonly allow resin impregnated liners that had a 50% minimum additive of ahighly specialized fire retardant as part of the resin mix used withinthe tubular liners. As a direct consequence of this, the traditionalthermal cured resins were unable to perform under such conditions, sincethe additive had an adverse affect when trying to cure the product usingheat. The devices and methods of the present invention were used, allwithout the need to gain entry or send personnel and equipment to thedownstream location of this particular storm drain. As per the previousexample, the pipe turned out to be 10 inches in diameter and was 340feet in length. A part of the apparatus within the method of thisinvention was used similarly to what is shown in FIGS. 8A-H. A decisionwas made to push the liner into place using its steep inclination and alot of lubrication, and a camera was sent down the pipe to both confirmthe exact length and to ensure the pipe was clean. The UV resinsaturated tubular liner encased with a UV protective sleeve was laidflat out flat on the road and measured for the exact length required,the liner was cut to length with the exposed ends being sealedimmediately following the cut for protection against light, the excessmaterial was placed back in its transportation box. After erecting a UVlight protective canopy, the tubular liner was loaded onto the pipe andallowed to slide down the incline using some more lubrication and water,when the liner finally reached the downstream end which tookapproximately 40 minutes, a clear translucent tubular coating wasinverted into the pipe, at the halfway position, the air beingevacuated, a small light device was attached to the trailing end or tailof the coating the inversion began again and at 2 psi the coating hadpulled the light train into place at the far end, we increased thepressure to 3 psi turned on the high power to the lights and set theretrieval speed after 10 minutes to 12 feet per minute, after retrievingthe equipment the video inspection camera was deployed to see the finalcured product of one continuous liner now in place in the canyon.

The apparatus and method of this invention can be used for theinstallation of any cured-in-place dry liner product, once impregnatedwith a light sensitive resin material and delivered to site, inverted,pulled or pushed into place or into any conduit (e.g., manhole,pipeline, or vertical shaft) used to convey fluids or gas. In the methodof the present invention, the length of time required for installing andcuring the liner will depend on a variety of factors, such as, e.g.,thickness and diameter of the liner, the size and capacity of the airsupply, the size and length and of the light activator.

The invention illustratively described herein can suitably be practicedin the absence of any element or elements, limitation or limitations,not specifically disclosed herein. Thus, for example, the terms“comprising,” “including,” “containing,” etc. shall be read expansivelyand without limitation. Additionally, the terms and expressions employedherein have been used as terms of description and not of limitation, andthere is no intention in the use of such terms and expressions ofexcluding any equivalents of the future shown and described or anyportion thereof, and it is recognized that various modifications arepossible within the scope of the invention claimed. Thus, it should beunderstood that although the present invention has been specificallydisclosed by preferred embodiments and optional features, modificationand variation of the inventions herein disclosed can be resorted bythose skilled in the art, and that such modifications and variations areconsidered to be within the scope of the inventions disclosed herein.The inventions have been described broadly and generically herein. Eachof the narrower species and sub-generic groupings falling within thescope of the generic disclosure also form part of these inventions. Thisincludes the generic description of each invention with a proviso ornegative limitation removing any subject matter from the genus,regardless of whether or not the excised materials specifically residedtherein.

In addition, where features or aspects of an invention are described interms of the Markush group, those schooled in the art will recognizethat the invention is also thereby described in terms of any individualmember or subgroup of members of the Markush group. It is also to beunderstood that the above description is intended to be illustrative andnot restrictive. Many embodiments will be apparent to those of ordinaryskill in the art upon reviewing the above description. The scope of theinvention should therefore, be determined not with reference to theabove description, but should instead be determined with reference tothe appended claims, along with the full scope of equivalents to whichsuch claims are entitled. The disclosures of all articles andreferences, including patent publications, are incorporated herein byreference.

It will be apparent to those skilled in the art that numerousmodifications and variations of the described examples and embodimentsare possible in light of the above teaching. The disclosed examples andembodiments may include some or all of the features disclosed herein.Therefore, it is the intent to cover all such modifications andalternate embodiments as may come within the true scope of thisinvention.

1. A method for repairing a hollow conduit having an inside wallsurface, said method comprising: taking a bladder having a lightactivator positioned therein, wherein the light activator includesmultiple light source strips wrapped around a flexible tube;impregnating a liner with a light-activated resin; forming a repairassembly by positioning the liner on the outside of the bladder;operatively attaching the light activator to a power hose configured toprovide power to the light activator from a power source; pushing orpulling the repair assembly into the hollow conduit; expanding thebladder using fluid pressure to urge the liner toward the inside wallsurface of the hollow conduit; and activating the light activator byproviding power to the multiple light source strips to help initiatecuring of the light-activated resin.
 2. The method of claim 1 whereinthe expandable bladder forms part of a packer.
 3. The method of claim 1further comprising allowing the light-activated resin to cure andharden.
 4. The method of claim 3 further comprising removing the bladderand light activator from the hollow conduit.
 5. The method of claim 1wherein the step of operatively attaching the light activator to a powerhose is performed before the step of forming a repair assembly.
 6. Themethod of claim 1 wherein a fluid is applied through the power hose toexpand the bladder.
 7. The method of claim 1 wherein the repair assemblyis pushed or pulled into the conduit by pushing or pulling the powerhose.
 8. The method of claim 1 wherein the light activator has a firstportion and a second portion, and the method further comprisingproviding power to both the first portion and the second portion of thelight activator.
 9. The method of claim 9 wherein the first portion ofthe light activator is a first end and the second portion of the lightactivator is a second end.
 10. The method of claim 10 further comprisingproviding power to the light activator at an intermediate portionbetween the first end and the second end.
 11. The method of claim 1wherein at least one of the multiple light source strips has a first endand a second end, and the method further comprises providing power toboth the first end and the second end.
 12. The method of claim 1 whereineach of the multiple light source strips has a first end and a secondend, and the method further comprises providing power to both the firstends and the second ends.
 13. The method of claim 1 further comprisingpositioning a flexible UV resistant tube on the outside of the linerbefore the repair assembly is pushed or pulled into the hollow conduitto help prevent premature curing of the light-activated resin.
 14. Themethod of claim 13 wherein each of the multiple light source strips ispowered by the power source.
 15. The method of claim 1 wherein the fluidpressure is air pressure.
 16. A method for repairing a hollow conduithaving an inside wall surface, said method comprising: taking a bladderhaving a light activator having a first end and a second end positionedtherein, wherein the light activator includes multiple light sourcestrips wrapped around a flexible tube; impregnating a liner with alight-activated resin; forming a repair assembly by positioning theliner on the outside of the bladder; operatively attaching the lightactivator to a power hose configured to provide power to the lightactivator from a power source; pushing or pulling the repair assemblyinto the hollow conduit by pushing or pulling the power hose; providinga fluid through the power hose to the bladder to expand the bladder andurge the liner toward the inside wall surface of the hollow conduit;providing power to the first end and the second end of the lightactivator in a two-way continuous power circuit to emit light from themultiple light source strips and help initiate curing of thelight-activated resin; allowing the light-activated resin to cure andharden; and removing the bladder and light activator from the hollowconduit.
 17. The method of claim 16 further comprising positioning aflexible UV resistant tube on the outside of the liner before the repairassembly is pushed or pulled into the hollow conduit to help preventpremature curing of the light-activated resin.
 18. The method of claim16 wherein each of the multiple light source strips has a first end anda second end, and the method further comprises providing power to boththe first ends and the second ends.
 19. The method of claim 18 whereineach of the multiple light source strips is powered by the power source.20. The method of claim 16 further comprising providing power to thelight activator at an intermediate portion between the first end and thesecond end.
 21. The method of claim 16 wherein at least one of themultiple light source strips has a first end and a second end, and themethod further comprises providing power to both the first end and thesecond end.
 22. A method for repairing a hollow conduit having an insidewall surface, said method comprising: taking a translucent bladderhaving a light activator positioned therein, wherein the light activatorhas a first portion and a second portion and includes multiple lightsource strips wrapped around a flexible tube; impregnating a liner witha light-activated resin; forming a repair assembly by positioning theliner around the bladder; attaching the light activator to a power hoseconfigured to provide power to the light activator from a power source;pushing or pulling the repair assembly into the hollow conduit;directing a fluid through the power hose into the bladder to expand thebladder and urge the liner toward the inside wall surface of the hollowconduit; providing power to the first portion and the second portion ofthe light activator in a two-way continuous power circuit to emit lightfrom the multiple light source strips and help initiate curing of thelight-activated resin; allowing the light-activated resin to cure andharden; and removing the bladder and light activator from the hollowconduit.
 23. The method of claim 22 wherein the first portion is a firstend of the light activator and the second portion is a second end of thelight activator.
 24. The method of claim 22 wherein the step ofattaching the light activator to a power hose is performed before thestep of forming a repair assembly.
 25. The method of claim 22 furthercomprising providing power to the light activator at an intermediateportion between the first portion and the second portion.
 26. The methodof claim 22 wherein at least one of the multiple light source strips hasa first end and a second end, and the method further comprises providingpower to both the first end and the second end.
 27. The method of claim22 wherein each of the multiple light source strips has a first end anda second end, and the method further comprises providing power to boththe first ends and the second ends.
 28. The method of claim 27 whereineach of the multiple light source strips is powered by the power source.29. A method for repairing a hollow conduit having an inside wallsurface, said method comprising: taking a translucent bladder havingmultiple light source strips wrapped around a flexible tube, wherein atleast one of the multiple light source strips has a first end and asecond end; impregnating a liner with a light-activated resin; forming arepair assembly by positioning the liner around the bladder; attachingthe multiple light source strips to a power hose configured to providepower to the multiple light source strips from a power source; pushingor pulling the repair assembly into the hollow conduit; directing afluid through the power hose into the bladder to expand the bladder andurge the liner toward the inside wall surface of the hollow conduit;providing power to the first end and the second end of at least one ofthe multiple light source strips in a two-way continuous power circuitto emit light from the at least one multiple light source strips andhelp initiate curing of the light-activated resin; allowing thelight-activated resin to cure and harden; and removing the bladder andlight activator from the hollow conduit.